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202:(a process step, therefore a poka-yoke) prior to starting an automobile. The interlock serves to prevent unintended movement of the car. Another example of poka-yoke would be the car equipped with an automatic transmission, which has a switch that requires the car to be in "Park" or "Neutral" before the car can be started (some
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in the 1960s to industrial processes designed to prevent human errors. Shingo redesigned a process in which factory workers, while assembling a small switch, would often forget to insert the required spring under one of the switch buttons. In the redesigned process, the worker would perform the task
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require the brake pedal to be depressed as well). These serve as behavior-shaping constraints as the action of "car in Park (or
Neutral)" or "foot depressing the clutch/brake pedal" must be performed before the car is allowed to start. The requirement of a depressed brake pedal to shift most of the
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When automobiles first started shipping with on-board GPS systems, it was not uncommon to use a forcing function which prevented the user from interacting with the GPS (such as entering in a destination) while the car was in motion. This ensures that the driver's attention is not distracted by the
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The microwave oven provides another example of a forcing function. In all modern microwave ovens, it is impossible to start the microwave while the door is still open. Likewise, the microwave will shut off automatically if the door is opened by the user. By forcing the user to close the microwave
252:
in two steps, first preparing the two required springs and placing them in a placeholder, then inserting the springs from the placeholder into the switch. When a spring remained in the placeholder, the workers knew that they had forgotten to insert it and could correct the mistake effortlessly.
215:
door while it is in use, it becomes impossible for the user to err by leaving the door open. Forcing functions are very effective in safety critical situations such as this, but can cause confusion in more complex systems that do not inform the user of the error that has been made.
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that holds pieces for processing might be modified to only allow pieces to be held in the correct orientation, or a digital counter might track the number of spot welds on each piece to ensure that the worker executes the correct number of welds.
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in the production. Defects occur when the mistakes are allowed to reach the customer. The aim of poka-yoke is to design the process so that mistakes can be detected and corrected immediately, eliminating defects at the source.
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process, but that if appropriate poka-yokes are implemented, then mistakes can be caught quickly and prevented from resulting in defects. By eliminating defects at the source, the cost of mistakes within a company is reduced.
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to prevent the agent from seeing or hearing the credit card information so that it cannot be stolen. The customer punches the information into their phone keypad, the tones are masked to the agent and are not visible in the
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GPS. However, many drivers found this feature irksome, and the forcing function has largely been abandoned. This reinforces the idea that forcing functions are not always the best approach to shaping behavior.
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cars with an automatic transmission from "Park" to any other gear is yet another example of a poka-yoke application. Over time, the driver's behavior is conformed with the requirements by repetition and habit.
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Either the operator is alerted when a mistake is about to be made, or the poka-yoke device actually prevents the mistake from being made. In Shingo's lexicon, the former implementation would be called a
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de
Bucourt, Maximilian; Busse, Reinhard; GĂŒttler, Felix; Wintzer, Christian; Collettini, Federico; Kloeters, Christian; Hamm, Bernd; TeichgrĂ€ber, Ulf K. (2011).
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Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an error can be made. For example, a
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More broadly, the term can refer to any behavior-shaping constraint designed into a process to prevent incorrect operation by the user.
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A typical feature of poka-yoke solutions is that they don't let an error in a process happen. Other advantages include:
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Architectures of
Control in Design, a site looking at constraints in the design of products, systems and environments
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A simple poka-yoke example is demonstrated when a driver of the car equipped with a manual gearbox must press on the
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is a
Japanese term that means "mistake-proofing" or "error prevention". It is also sometimes referred to as a
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method identifies product defects by testing the product's shape, size, color, or other physical attributes.
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Standardized Work with TWI: Eliminating Human Errors in
Production and Service Processes
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Standardized Work with TWI: Eliminating Human Errors in
Production and Service Processes
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Shingo recognized three types of poka-yoke for detecting and preventing errors in a
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A poka-yoke is any mechanism in a process that helps an equipment operator avoid (
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A study of the Toyota production system from an industrial engineering viewpoint
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These forcing functions are being used in the service industry as well.
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as they occur. The concept was formalized, and the term adopted, by
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The
Sayings of Shigeo Shingo: Key Strategies for Plant Improvement
592:. Springer tracts in mechanical engineering. Singapore: Springer.
64:) and defects by preventing, correcting, or drawing attention to
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Zero quality control: source inspection and the poka-yoke system
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Promotion of the work improvement-oriented approach and actions;
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Shingo distinguished between the concepts of inevitable human
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Lockton, Dan; Harrison, David; Stanton, Neville A. (2010).
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Poka-yoke: improving product quality by preventing defects
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Poka-yoke: improving product quality by preventing defects
662:"Error-proofing strategies for managing call center fraud"
506:"A Brief Tutorial on Mistake-proofing, Poka-Yoke, and ZQC"
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432:"Using Poka-Yoke Techniques for Early Defect Detection"
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Process that helps an equipment operator avoid mistakes
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poka-yoke, while the latter would be referred to as a
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Unburdening of operators from repetitive operations;
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725:"Poka Yoke or Mistake Proofing :: Overview"
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952:Mistake-Proofing - Fool-Proofing - Failsafing
121:that means avoiding an unthinkably bad move.
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590:Quality management practices in MSME sectors
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163:. Unsourced material may be challenged and
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350:Elimination of many operations related to
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183:Learn how and when to remove this message
95:, but as this means "fool-proofing" (or "
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508:. John Grout's Mistake-Proofing Center.
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99:") the name was changed to the milder
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475:. Portland, OR: Productivity Press.
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347:Less time spent on training workers;
339:Benefits of poka-yoke implementation
161:adding citations to reliable sources
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894:Hinckley, C. M.; P. Barkan (1995).
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660:Adsit, Dennis (February 21, 2011).
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247:The term poka-yoke was applied by
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1189:Failure mode and effects analysis
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512:from the original on Apr 14, 2009
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375:Detecting mistakes as they occur;
925:. New York: Productivity Press.
791:. New York: Productivity Press.
237:customer relationship management
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688:. QualityCoach.Net. July 1987.
504:John R. Grout, Brian T. Downs.
268:Implementation in manufacturing
912:10.1080/00224065.1995.11979596
760:. Productivity Press. p.
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369:100% built-in quality control;
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1060:Total productive maintenance
1045:Single-minute exchange of die
1030:Continuous-flow manufacturing
947:Mistake-proofing example wiki
900:Journal of Quality Technology
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631:10.1016/j.apergo.2009.09.001
588:Sharma, Rajiv Kumar (2021).
363:A reduced number of rejects;
103:. Poka-yoke is derived from
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43:behavior-shaping constraint
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84:Poka-yoke was originally
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1286:Toyota Production System
1158:Business process mapping
1025:Muri - Standardized work
430:Robinson, Harry (1997).
74:Toyota Production System
1276:Japanese business terms
204:automatic transmissions
1005:Cellular manufacturing
871:: Productivity Press.
828:: Productivity Press.
1210:Design of experiments
1132:Voice of the customer
537:Insights into Imaging
1137:Value-stream mapping
859:Nikkan Kogyo Shimbun
750:Nikkan Kogyo Shimbun
727:. The Quality Portal
442:on December 27, 2014
157:improve this section
1184:Root cause analysis
1055:Production leveling
702:on January 28, 2014
1281:Lean manufacturing
1163:Process capability
1015:Muda - Over burden
993:Lean manufacturing
619:Applied Ergonomics
125:Usage and examples
32:[pokajoke]
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224:credit card fraud
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308:motion-step
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1270:Categories
706:August 20,
415:References
239:software.
230:are using
1246:Poka-yoke
1112:Six Sigma
1050:Poka-yoke
1040:Five whys
1010:Takt time
887:300302752
666:iSixSigma
557:1869-4101
404:Interlock
394:Fail-safe
144:does not
101:poka-yoke
80:Etymology
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861:(1988).
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818:(1986).
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383:See also
312:sequence
284:system:
257:mistakes
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325:control
321:warning
290:contact
274:fixture
261:defects
243:History
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52:yokeru
1257:DMAIC
1142:SIPOC
1114:tools
995:tools
643:S2CID
119:shogi
91:-yoke
41:or a
927:ISBN
883:OCLC
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851:2009
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635:PMID
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518:2009
487:OCLC
477:ISBN
448:2009
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